Optical coupling device with waveguide assisted registration

ABSTRACT

A multi-piece optical coupling device comprises a first piece that includes one or more first receiving elements configured to receive and secure one or more optical waveguides. The first piece further includes one or more light affecting elements configured to affect one or more characteristics of light from the optical waveguides while propagating the light within the optical coupling device. A second piece is separate from the first piece and includes one or more second receiving elements configured to receive the waveguides, the first receiving elements and the second receiving elements configured to align the second piece and the first piece using the optical waveguides. The second piece also includes one or more mating alignment features configured to engage with a mating optical coupling device and to align the optical coupling device with the mating optical coupling device.

TECHNICAL FIELD

This disclosure relates generally to optical coupling devices such asoptical ferrules and optical connectors.

BACKGROUND

Optical coupling devices such as optical connectors and optical ferrulesallow light from a one or more waveguides to pass through a firstconnector to a corresponding set of waveguides of a mating secondconnector. The mating devices mechanically couple together and alignoptical elements of the first device with optical elements of the matingdevice. Optical coupling devices can be used for optical communicationsin a variety of applications including telecommunications networks,local area networks, data center links, and internal links in computerdevices.

BRIEF SUMMARY

Embodiments described herein are directed to multi-piece opticalcoupling device. According to some embodiments, a first piece includesone or more first receiving elements configured to receive and secureone or more optical waveguides. The first piece further includes one ormore light affecting elements configured to affect one or morecharacteristics of light from the optical waveguides while propagatingthe light within the optical coupling device. A second piece is separatefrom the first piece and includes one or more second receiving elementsconfigured to receive the waveguides, the first receiving elements andthe second receiving elements configured to align the second piece andthe first piece using the optical waveguides. The second piece alsoincludes one or more mating alignment features configured to engage witha mating optical coupling device and to align the optical couplingdevice with the mating optical coupling device.

According to some embodiments, a first piece includes one or more firstreceiving elements configured for receiving and securing one or moreoptical waveguides. The first piece also includes one or more firstmating alignment features configured to align the optical couplingdevice with a mating optical coupling device. A second piece, separatefrom the first piece, includes one or more second receiving elementsconfigured for receiving the waveguides, the first receiving elementsand the second receiving elements configured to align the second pieceand the first piece using the optical waveguides. The second piece alsoincludes one or more second mating alignment features configured toengage with a mating optical coupling device and to align the opticalcoupling device with a mating optical coupling device. The matingfeatures may additionally provide a retention function to hold theoptical coupling device with a mating optical coupling device togetherafter mating.

BRIEF DESCRIPTION OF DRAWINGS

FIGS. 1A through 1E are various views of a two-piece optical couplingdevice that provides for waveguide-assisted registration between thepieces in accordance with some embodiments;

FIGS. 2A through 2E provide various views of a two-piece opticalcoupling device that provides for waveguide-assisted registrationbetween the pieces in accordance with some embodiments;

FIG. 3 is a cross sectional view of a portion of an optical couplingdevice that includes grooves on the first and second pieces configuredto receive waveguides for fiber assisted registration between the firstand second pieces; and

FIGS. 4 and 5 provide cross sectional views of portions of opticalcoupling devices wherein a waveguide array is used to register the firstpiece of an optical coupling device to a second piece of an opticalcoupling device in accordance with some embodiments.

The figures are not necessarily to scale. Like numbers used in thefigures refer to like components. However, it will be understood thatthe use of a number to refer to a component in a given figure is notintended to limit the component in another figure labeled with the samenumber.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Embodiments disclosed herein relate to waveguide-assisted registrationof multi-piece optical coupling devices. An optical coupling device,such as an optical connector or optical ferrule, also referred to hereinas a light coupling unit, can include one or more elements for receivingand securing one or more optical waveguides and one or more matingalignment features for aligning the optical coupling device with amating optical coupling device. Some optical coupling devices providefor direct waveguide-to-waveguide optical coupling. Other opticalcoupling devices may include one or more optical elements disposed inthe optical path between a waveguide and a mating waveguide, the opticalelements affecting one or more characteristics of light from the opticalwaveguides as the light propagates through the optical coupling device.For example, the optical elements may comprise mirrors and/or lensesthat affect one or more of the direction and the divergence of lightfrom the waveguides.

Good quality coupling of optical signals through an optical interfacerequires relative positioning of all optical components along the signalpath. Mechanical mating alignment features of an optical coupling devicealign the optical coupling device with a mating optical coupling device.In embodiments that use direct waveguide-to-waveguide coupling, theelements of the optical coupling device that receive and secure theoptical waveguides aim the waveguides, and thus the optical signal,toward the waveguides of the mating optical coupling device. If theoptical coupling device uses light affecting elements, e.g., lenses ormirrors, in the light signal path, the light affecting elements mayfurther aim and/or focus the optical signal from the waveguides towardlight affecting elements of the mating optical coupling device.

Embodiments described herein provide approaches for reducing variationloss of the optical signal passing through the optical interface.Variation in the optical signal can arise from misalignment of variousfeatures within the optical coupling device. Variation in the opticalsignal can arise due to alignment error between the light affectingelements, e.g., lenses, mirrors, etc., of an optical coupling device andthe mating alignment features of the optical coupling device. Approachesdescribed in this disclosure involve assembling an optical couplingdevice using waveguides to register the optical elements to the matingalignment features within the optical coupling device.

Variation in the optical signal can arise due to the difference inthermal expansion between the optical waveguide material and thecomponent that secures the waveguides. For example, optical waveguidesmay be made of materials such as glass, which has a lower coefficient ofthermal expansion when compared with the coefficient of thermalexpansion of materials like injection-molded thermoplastics (e.g. liquidcrystal polymers) used to make the ferrule shell or other component thatsecures the waveguides. Approaches described in this disclosure involvesecuring the optical waveguides between components made of materialshaving the same or similar coefficient of thermal expansion. Securingthe optical waveguides between components having the same or similarcoefficients of thermal expansion can reduce misalignment of thewaveguides due to bending or warping of the ferrule or other componentsto which the waveguides are secured.

Furthermore, embodiments described herein provide approaches forenhancing the optical signal through the use of appropriate selection ofmaterials. For example, materials particularly suited for use asmechanical mating alignment features may differ from materials that areparticularly suited to form light affecting elements such as lensesand/or mirrors. When the optical coupling device includes lightaffecting elements, it is sometimes beneficial to use a first materialto form the first piece of the optical coupling device that includes thelight affecting elements and to use a second material to form the secondpiece that includes mating alignment features. The use of differentmaterials for the first and second pieces allows the materials used foreach piece to be better suited for its particular function. For example,the first piece may be made of an optical polymer such aspolyetherimide, and the second piece may be made of a structural polymersuch as a glass-particle-loaded thermoplastic, or a liquid crystalpolymer. The second piece could also be metal, e.g. die-cast zinc.

Optical coupling devices disclosed herein are multi-piece couplingdevices comprising at least a first piece and a second piece with one ormore waveguides secured between the first and second pieces of theoptical device. The embodiments discussed herein illustratewaveguide-assisted registration between multiple pieces of the opticalcoupling device. In some embodiments, a first piece of the opticalcoupling device includes receiving elements for receiving and securingthe optical waveguides. The first piece also includes light affectingelements that affect one or more characteristics of light from theoptical waveguides as the light propagates in the optical couplingdevice. A second piece of the optical coupling device includes themating alignment features. In some embodiments, a first piece of theoptical coupling device includes the receiving elements and fine matingalignment features and a second piece of the optical coupling deviceincludes coarse mating alignment features.

Registration of the first piece of the optical coupling device to thesecond piece of the optical coupling device is achieved by registeringthe first and second pieces to waveguide fibers or an to array ofwaveguides. In some embodiments, each of the pieces of a multi-pieceoptical device may be a unitary molded piece. In some embodiments, atleast one of the pieces, e.g., the second piece, may include a latch forsecuring the optical coupling device to a mating optical couplingdevice.

FIGS. 1A through 1E provide various views of a two-piece opticalcoupling device 100 that provides for waveguide assisted registrationbetween the first piece 101 and the second piece 102. FIG. 1A is anexploded perspective view of an optical coupling device 100 inaccordance with some embodiments. The first piece 101 includes one ormore first receiving elements 111 configured to receive and secure oneor more optical waveguides 105, e.g., optical waveguide fibers. The termoptical waveguide is used herein to refer to an optical element thatpropagates signal light. An optical waveguide comprises at least onecore with a cladding, wherein the core and cladding are configuredpropagate light within the core, e.g., by total internal reflection. Anoptical waveguide may be, for example, a single core fiber, a multi-coreoptical fiber, or a polymeric waveguide. A waveguide may have anysuitable cross sectional shape, e.g., circular, square, rectangular etc.In the illustrated embodiment, the first piece 101 of the opticalcoupling device 100 also includes one or more light affecting elements112 configured to affect light from the optical waveguides 105 as thelight propagates through the optical coupling device 100.

The second piece 102 of the optical coupling device 100 includes one ormore second receiving elements 115 configured to receive and secure theoptical waveguides 105. The second piece 102 also includes mechanicalmating alignment features 113 configured to align the optical couplingdevice 100 with a mating optical coupling device 129 (not shown in FIG.1A but shown in FIGS. 1D and 1E).

In the embodiment illustrated in FIGS. 1A through 1E, the firstreceiving elements 111 comprise grooves, each groove 111 configured toreceive and secure a portion 106 of an optical waveguide fiber 105 thathas the buffer coating stripped away, exposing the cladding of thewaveguide. The second piece 102 includes grooves 115 that are configuredto receive and secure the portion 106 of the optical waveguide fibers105. In various embodiments, the first piece 101 and the second piece102 may have the same number of grooves 111, 115 and/or the generalshape and/or pattern of the grooves 115. In alternative embodiments, thegrooves of the first piece and the grooves of the second piece maydiffer in shape, number and/or pattern.

FIG. 1B provides an exploded perspective view of the optical couplingdevice 100 showing the exposed portions 106 of optical waveguides 105disposed and secured in the grooves 115 of the second piece 102. Whenthe two pieces 101, 102 of the optical coupling device 100 are assembledtogether, as illustrated in FIG. 1C, the bare optical waveguide portions106 collectively serve as a registration feature that aligns the firstpiece 101 with the second piece 102.

The mating alignment features shown in FIGS. 1A through 1E comprise arms113 that extend from the second piece 102 along the mating axis 121 ofthe optical coupling device 100. In some embodiments, after mating withthe mating optical coupling device 129, the arms 113 control alignmentof the optical coupling device 100 along the mating axis 121 and/oralong the lateral axis 122 which is orthogonal to the mating axis 121.For example, to control mating axis or lateral axis alignment, the arms113 may directly engage compatible features on the mating opticaldevice.

In some embodiments, the arms 113 can be flexible and designed toflexibly press against the sides of the mating optical coupling device.Flexible side arms 113 facilitate alignment of the light affectingelements 112 of the optical coupling device 100 and the light affectingelements of the mating optical coupling device. In equilibrium, theforces created by the flexing of the four arms of the optical couplingdevice and the mating optical coupling device balance to align theoptical coupling devices relative to each other. In some embodiments,the ends of the arms provide forward stops that control translationalong the mating axis 121.

The material forming the compliant features and/or the geometry of thecompliant features can be selected to provide a desired alignment forcebetween ferrules. For example, the alignment force provided by thecompliant features can be increased or decreased by choosing a materialfor the compliant features with a higher or lower Young's modulus,respectively. As another example, in embodiments utilizing flexiblearms, the alignment force provided by the flexible arms can be increasedor decreased by choosing larger or smaller cross-sectional areas,respectively, for the flexible arms. Useful alignment forces can beobtained by choosing an injection moldable polymer for both a body ofthe ferrule and the compliant features of the ferrule and by choosing ageometry of the compliant features that can be injection molded alongwith the body of the ferrule. In this way, for example, a unitaryferrule having compliant features that provide a desired alignment forcecan be made in an injection molding process. Additional detailsregarding optical ferrules and/or flexible alignment features areprovided in commonly owned and concurrently filed U.S. patentapplication Ser. No. 62/240,066, having the title “Ferrules, AlignmentFrames and Connectors,” and U.S. patent application Ser. No. 62/240,069,having the title “Optical Ferrules” and which is incorporated herein byreference.

In some embodiments, the optical coupling device 100 includes a latchingmechanism that is configured to secure the optical coupling device 100to a mating optical coupling device 129 after the optical couplingdevices 100, 129 are mated. This may be accomplished by providing theflexible side arms 113 with features (e.g. a protrusion) which caninterlock with a corresponding feature (e.g. a recess) in the matingconnector. Such a configuration can produce a retaining force along themating direction that holds the mating connectors together, that is,provides alignment along the mating direction. A suitable latchingmechanism for securing the optical coupling devices 100, 129 togetherafter mating is described in commonly owned and concurrently filed U.S.patent application Ser. No. 62/239,998 having the title “Connector withLatching Mechanism,” and which is incorporated herein by reference.

FIG. 1D shows a bottom view of the optical coupling device 100 and a topview of a mating optical coupling device 129 just prior to mating. FIG.1E shows the optical coupling device 100 and the mating optical couplingdevice 129 after mating. The bottom view of the optical coupling device100 shown in FIG. 1D depicts a sliding surface 107 that includes anoptical input/output window 109 disposed in the first piece 101. Thesliding surface 107 is configured to slide against a compatible matingsurface during mating of the optical coupling device 100 and the matingoptical coupling device 129. In the embodiment shown in FIGS. 1A through1E, light from the waveguides 105 propagating in the optical couplingdevice 100 is redirected by light affecting elements 112 and exits theoptical coupling device 100 after being transmitted by the opticalinput/output window 109. The mating optical coupling device 129 receivesthe light through its input/output window and the light affectingelements of the mating optical coupling device redirect the light intothe waveguides attached to the mating optical coupling device.

In some embodiments, as shown in FIG. 1D, the second piece 102 mayinclude a cavity 108 and/or first and second clip portions 108 a, 108 bconfigured to hold the first piece 101. Assembling the two-piece opticalcoupling device 100 can involve adhesively securing portions 106 of thewaveguides 105 to the receiving and securing elements 115 of the secondpiece 102. The first piece 101 is then inserted at least partially intothe cavity 108 of the second piece 102 and the first piece 101 issecured by the clips 108 a, 108 b. The clips 108 a, 108 b are configuredto exert a force on the first piece 101 along the thickness axis 123which is orthogonal to the mating and lateral axes 121, 122 to retainthe first piece 101 in the cavity 108 of the second piece 102.

As the first piece 101 is inserted into the second piece 102,waveguide-assisted registration between the first and second pieces 101,102 occurs. The receiving elements 111 of the first piece 101 receivethe portions 106 of the waveguides 105 that are secured to elements 115of the second piece 102, thus aligning the first piece 101 with thesecond piece 102 using the waveguides 105 as the registration featurebetween the two pieces 101, 102. The waveguide portions 106 are secured,e.g., by an adhesive, to the elements receiving of the first piece 101.In an alternative approach, the waveguide portions 106 may be firstsecured to the first piece 101, such that when the first piece 101 isinserted into the cavity 108 of the second piece 102, the waveguideportions 106 secured to the first piece 101 engage the grooves 115 ofthe second piece 102 registering the second piece 102 to the first piece101. In another alternative approach, the first and second pieces areassembled over the waveguides, and then adhesive is applied to theassembly, using surface tension to pull the adhesive along thewaveguides and receiving elements.

FIGS. 2A through 2E provide various views of a two-piece opticalcoupling device 200 that provides for waveguide-assisted registrationbetween the pieces 201, 202. In this embodiment, the first piece 201includes fine mating alignment features 214 and the second piece 202includes coarse mating alignment features 213. The coarse matingalignment features 213 are configured to provide for mating alignmentwith a mating optical device with a more relaxed mating tolerance whencompared to the fine mating alignment features 214 which provide matingalignment with a relatively tighter tolerance. In some embodiments, thesecond (coarse) mating alignment features are configured to engage withcompatible mating alignment features of the mating optical couplingdevice before engagement of the first (fine) mating alignment features.In some embodiments, the coarse mating alignment features 213 providepositive retaining force to hold the first pieces of the matingconnectors together, thus ensuring seating of the fine alignmentfeatures 214, and optical alignment along the mating direction.

Waveguide-assisted registration of the first and second pieces 202 ofthe optical coupling device provides for precise alignment of the coarse213 and fine 214 mating alignment features of the optical couplingdevice 200. The optical coupling devices that employ waveguide assistedregistration as described herein may include first and/or second piecesthat are hermaphroditic (including both male and female components) orthe first and/or second pieces may be non-hermaphroditic. In theembodiments shown in FIGS. 2A through 2E, the fine alignment features214 of the first piece are non-hermaphroditic.

FIGS. 2A and 2B are perspective views of a first piece 201 and a secondpiece 202 of the optical coupling device 200 prior to assembling theoptical coupling device. The first piece 201 includes one or moreelements 211 configured to receive and secure one or more opticalwaveguides 205 and fine mating alignment features comprising pins 214that extend from the first piece along the mating axis 121. The pins 214are configured to engage with compatible sockets of a mating opticalcoupling device.

The second piece 202 includes one or more elements 215 configured toreceive and secure the optical waveguides 205 and also includes coarsemating alignment features 213. The coarse mating alignment features 213and the fine mating alignment features 214 are configured to providecourse and fine alignment, respectively, between the optical couplingdevice 200 with a mating optical coupling device 229 (not shown in FIG.2A but shown in FIGS. 2D and 2E). The coarse alignment features 213engage with the mating connector first, thereby assisting in guiding thefine alignment features 214 into registration with mating fine alignmentfeatures.

In the embodiment illustrated in FIG. 2A through 2E, the receiving andsecuring elements 211 of the first piece 201 comprise grooves, eachgroove 211 configured to receive and secure a portion 206 of an opticalwaveguide fiber 205 that has the buffer coating stripped away exposingthe cladding of the waveguide. Although waveguide assisted registrationcan alternatively be accomplished using waveguides having the buffercoating intact, more precise alignment is accomplished using barewaveguide portions 206. As depicted in FIGS. 2A and 2B, the second piece202 includes grooves 215 that are configured to receive and secure theoptical waveguide fibers 205 which are similar in shape, pattern andnumber to grooves 211. When the two pieces 201, 202 of the opticalcoupling device 200 are assembled together, as shown in FIG. 2C, thebare optical waveguide portions 206 collectively serve as a registrationfeature that aligns the first piece 201 with the second piece 202. Theoptical waveguides 205 can be secured to the grooves 211 and the grooves215 by an adhesive. The second piece 202 may include a cavity 208 asshown in FIGS. 2A and 2B and/or clips 208 a,b that serve to hold thefirst piece 201 in the cavity 208 of the second piece 202.

The optical coupling device 200 is assembled by bringing the first andsecond pieces 201, 202 together, e.g., by inserting the first piece 201into the cavity 208 of the second piece 202. As the first piece 210 isinserted into the cavity 208 of the second piece 202, fiber assistedregistration between the first and second pieces 201, 202 occurs. Thereceiving elements 211 of the first piece 201 receive the portions 206of the waveguides 205 that are secured to elements 215 of the secondpiece 202, thus aligning the first piece 201 with the second piece 202using the waveguides 205 as the registration feature between the twopieces 201, 202. The waveguide portions 206 are secured, e.g., by anadhesive, to the elements 211 of the first piece 201. In an alternativeapproach, the waveguide portions 206 may be first secured to thereceiving elements 211 of the first piece 201, such that when the firstpiece 201 is inserted into the cavity 208 of the second piece 202, thewaveguide portions 206 secured to the first piece 201 engage the grooves215 of the second piece 202 registering the second piece 202 to thefirst piece 201. First and second pieces may also be assembled over thewaveguides before adhesive is allowed to flow onto the waveguides andgrooves.

FIG. 2D shows a perspective view of the optical coupling device 200 anda mating optical coupling device 229 just prior to mating. FIG. 2E showsthe optical coupling device 200 and the mating optical coupling device229 after mating. In the embodiment shown in FIGS. 2A through 2E, theends of the waveguides 205 secured by the optical coupling device 200are stripped of their buffer coating, and the ends of the waveguides arecleaved and polished. After the optical coupling device 200 and themating optical coupling device 229 are mated, the polished ends of eachwaveguide 205 of the optical coupling device 200 are disposed in-lineand touching or in close proximity to a waveguide of the mating opticalcoupling device 229. Light from the waveguides 205 of the opticalcoupling device 200 is directed into the waveguides of the matingoptical coupling device 229 to provide the optical signal connection.The waveguides may also be polished after being bonded to the firstpiece (in which case the alignment pins are added after polishing).

After mating with a mating optical coupling device 229, the finealignment features 214 and the coarse alignment features 213 controlalignment of the optical coupling device 200 with the mating opticalcoupling device 229. In some embodiments, the optical coupling device200 includes a latching mechanism that is configured to secure theoptical coupling device 200 to a mating optical coupling device 229after the optical coupling devices 200, 229 are mated.

FIGS. 3 through 5 provide cross sectional views of several alternativeembodiments of elements configured for receiving and securing thewaveguides for fiber assisted registration as discussed herein. In manyembodiments, the receiving and securing elements of the first piece andthe receiving and securing elements of the second piece will have thesame general shape, number, and/or pattern. In some embodiments theshape, number, and/or pattern of and the receiving and securing elementsof the first piece and the receiving and securing elements of the secondpiece may differ.

FIG. 3 is a cross sectional view of a portion of an optical couplingdevice 300 that includes first and second pieces 301, 302 that includegrooves 311, 315 configured to receive and secure the waveguides 305. Anadhesive 306 is disposed between the waveguides 305 and the first andsecond pieces 301, 302 to secure the waveguides 305 to the first andsecond pieces 301, 302. The grooves are illustrated in FIG. 3 asv-shaped grooves, although grooves of any shape, e.g., u-shaped groovesor y-shaped grooves forming a rounded or square channel, could be used.Grooves that are suitable for use in a two piece optical coupling devicethat employs waveguide assisted registration are described in commonlyowned and concurrently filed U.S. patent application Ser. No.62/240,009, having the title “Optical Waveguide Registration Feature,”and which is incorporated herein by reference.

In some embodiments, the optical waveguides may be optical waveguidefibers shown in the embodiments discussed above. In some embodiments thewaveguides may be arranged as a waveguide array, e.g., a polymerwaveguide array. For example, in some embodiments the optical waveguidesmay comprise an array of one or more integrated optical waveguidesfabricated in a substrate. In some embodiments, the optical waveguidesmay be arranged in a waveguide array film. The waveguide array may beused to register the first piece to the second piece of a multi-pieceoptical coupling device.

FIGS. 4 and 5 provide cross sectional views of a portion of opticalcoupling devices 400, 500 wherein a waveguide array 405, 505 is used toregister the first piece 401, 501 to a second piece 402, 502 of anoptical coupling device 400, 500. FIGS. 4 and 5 illustrate a waveguidearray 405, 505, comprising waveguide cores 406, 506 arranged in a film407, 507 wherein the waveguide array 405, 505 is used for waveguideassisted registration of a first piece 401, 501 and a second piece 402,502 of an optical coupling device 400, 500. In the embodiment of FIG. 4,the second piece 402 includes waveguide assisted registration elementscomprising grooves 411 that are configured to engage with ridges 409 inthe waveguide array 405. The first piece 401 includes waveguide assistedregistration elements comprising ridges 415 in the array 405 that areconfigured to engage with grooves 419 in the second piece 402. In FIG.5, the waveguide assisted registration elements comprise ridges 511, 515in the first and second pieces 501, 502 that are configured to engagewith vias 508 through the waveguide film 505.

The materials used for the first and second pieces 301, 401, 501, 302,402, 502 may be the same or the material used for the first piece 301,401, 501 may be different from the material used for the second piece302, 402, 502. In some embodiments, the material of the first piece 301,401, 501 may be selected for its optical characteristics and suitabilityto form light affecting elements such as lenses and/or mirrors. Thematerial of the second piece 302, 402, 502 may be selected for itsmechanical properties and suitability to form mechanical matingalignment features. In some embodiments the coefficient of thermalexpansion of the material of the first piece 301, 401, 501 is similar orsubstantially equal to the coefficient of thermal expansion of thematerial of the second piece 302, 402, 502.

Additional information regarding ferrules, alignment frames, andconnectors that may be used in conjunction with the approaches describedherein is provided in the following commonly owned and concurrentlyfiled U.S. Patent Applications which are incorporated herein byreference: U.S. Patent Application Ser. No. 62/239,998, having the title“Connector with Latching Mechanism”; U.S. Patent Application Ser. No.62/240,069, having the title “Optical Ferrules”; U.S. Patent ApplicationSer. No. 62/240,066, having the title “Ferrules, Alignment Frames andConnectors,”; U.S. Patent Application Ser. No. 62/240,008, having thetitle “Optical Cable Assembly with Retainer,”; U.S. Patent ApplicationSer. No. 62/240,000, having the title “Dust Mitigating OpticalConnector,”; U.S. Patent Application Ser. No. 62/240,009, having thetitle “Optical Waveguide Registration Feature,”; U.S. Patent Application62/239,996, having the title “Optical Ferrules and Optical FerruleMolds,”; U.S. Patent Application 62/240,002, having the title “OpticalFerrules with Waveguide Inaccessible Space,”; U.S. Patent Application62/104,196, having the title “Configurable Modular Connectors,”; andU.S. Patent Application 62/240,005, having the title “HybridConnectors,”.

Items described in this disclosure include:

Item 1. An optical coupling device comprising:

-   -   a first piece comprising:        -   one or more first receiving elements configured to receive            and secure one or more optical waveguides; and        -   one or more light affecting elements configured to affect            one or more characteristics of light from the optical            waveguides while propagating the light within the optical            ferrule; and    -   a second piece, separate from the first piece, the second piece        comprising:        -   one or more second receiving elements configured to receive            the waveguides, the first receiving elements and the second            receiving elements configured to align the second piece and            the first piece using the optical waveguides; and        -   one or more mating alignment features configured to engage            with a mating optical coupling device and to align the            optical coupling device with the mating optical coupling            device.

Item 2. The optical coupling device of item 1, wherein the first pieceis a first unitary molded piece and the second piece is a second unitarymolded piece.

Item 3. The optical coupling device of any of items 1 through 2, whereinthe first piece comprises a first material and the second piececomprises a second material different from the first material.

Item 4. The optical coupling device of any of items 1 through 3, whereinthe first piece has a coefficient of thermal expansion that issubstantially the same as a coefficient of thermal expansion of thesecond piece.

Item 5. The optical coupling device of any of items 1 through 4, whereinthe first piece fits at least partially within a cavity the secondpiece.

Item 6. The optical coupling device of any of items 1 through 5, whereinthe second piece includes clips configured to hold the first piece.

Item 7. The optical coupling device of any of items 1 through 6, whereinthe first piece includes at least one mating alignment feature.

Item 8. The optical coupling device of item 7, wherein the at least onemating alignment feature of the first piece comprises a pin configuredto engage with a socket of a mating optical coupling device.

Item 9. The optical coupling device of any of items 1 through 8, whereinthe first piece includes a surface that is configured to slidably matewith a surface of a mating optical coupling device.

Item 10. The optical coupling device of any of items 1 through 9,wherein the one or more characteristics of the light propagating withinthe optical coupling device include one or more of a direction anddivergence of the light.

Item 11. The optical coupling device of any of items 1 through 10further comprising an output surface, the light propagating within theoptical coupling device exiting the optical coupling device after beingtransmitted by the output surface, the output surface disposed in thefirst piece.

Item 12. The optical coupling device of any of items 1 through 11,wherein the mating alignment features of the second piece compriseforward stops.

Item 13. The optical coupling device of any of items 1 through 12,wherein the mating alignment features of the second piece comprise armsthat extend from the second piece.

Item 14. The optical coupling device of item 13, wherein the arms areflexible.

Item 15. The optical coupling device of item 14, wherein the arms areconfigured to flexibly engage with sides of a mating optical couplingdevice and to provide lateral mating alignment between the opticalcoupling device that the mating optical coupling device.

Item 16. The optical coupling device of any of items 1 through 15,wherein at least one of the first and second receiving elements comprisegrooves.

Item 17. The optical coupling device of any of items 1 through 16,wherein the optical waveguides are optical fibers.

Item 18. The optical coupling device of any of items 1 through 15,wherein at least one of first and second receiving elements comprisesridges.

Item 19. The optical coupling device of item 1, wherein the opticalwaveguides are an array of one or more integrated optical waveguidesfabricated in a substrate.

Item 20. The optical coupling device of item 1, wherein the opticalwaveguides are arranged in a waveguide array film.

Item 21. The optical coupling device of item 20, wherein the waveguidefilm includes features configured to engage with at least one of thereceiving elements of the first piece and the second piece.

Item 22. The optical coupling device of item 21, wherein the features ofthe optical waveguide film comprise at least one of ridges, grooves, andvias.

Item 23. The optical coupling device of any of items 1 through 22,wherein the first piece and the second piece are pieces of an opticalferrule.

Item 24. The optical coupling device of any of items 1 through 23,wherein the first piece is an optical ferrule and the second piece is ahousing of an optical connector.

Item 25. An optical coupling device comprising:

-   -   a first piece comprising:        -   one or more first receiving elements configured for            receiving and securing one or more optical waveguides;        -   one or more first mating alignment features configured to            align the optical coupling device with a mating optical            coupling device; and    -   a second piece, separate from the first piece, the second piece        comprising:        -   one or more second receiving elements configured for            receiving the waveguides, the first receiving elements and            the second receiving elements configured to align the second            piece and the first piece using the optical waveguides; and        -   one or more second mating alignment features configured to            engage with a mating optical coupling device and to align            the optical coupling device with a mating optical coupling            device.

Item 26. The optical coupling device of item 25, wherein the first pieceis a first unitary molded piece and the second piece is a second unitarymolded piece.

Item 27. The optical coupling device of any of items 25 through 26,wherein the first piece comprises a first material and the second piececomprises a second material different from the first material.

Item 28. The optical coupling device of any of items 25 through 27,wherein the first piece has a coefficient of thermal expansion that isabout the same as a coefficient of thermal expansion of the secondpiece.

Item 29. The optical coupling device of any of items 25 through 28,wherein the first piece fits at least partially within a cavity thesecond piece.

Item 30. The optical coupling device of any of items 25 through 29,wherein the second piece includes clips configured to hold the firstpiece.

Item 31. The optical coupling device of any of items 25 through 30,wherein the first mating alignment features provide fine matingalignment and the second mating alignment features provide coarse matingalignment.

Item 32. The optical coupling device of any of items 25 through 31,wherein the first mating alignment features comprise pins or socketsconfigured to engage with a socket or pin of a mating optical couplingdevice.

Item 33. The optical coupling device of any of items 25 through 32,wherein the second mating alignment features comprise arms that extendfrom the second piece.

Item 34. The optical coupling device of items 25 through 33, wherein atleast one of the first and second receiving elements comprise grooves.

Item 35. The optical coupling device of items 25 through 34, wherein atleast one of first and second receiving elements comprise ridges.

Item 36. The optical coupling device of any of items 25 through 35,wherein the optical waveguides are optical fibers.

Item 37. The optical coupling device of any of items 25 through 36,wherein the optical waveguides are an array of one or more integratedoptical waveguides fabricated in a substrate.

Item 38. The optical coupling device of any of items 25 through 36,wherein the optical waveguides are arranged in a waveguide array film.

Item 39. The optical coupling device of item 38, wherein the waveguidearray film includes features configured to engage with at least one ofthe receiving elements of the first piece and the second piece.

Item 40. The optical coupling device of item 39, wherein the features ofthe optical waveguide film comprise at least one of ridges, grooves, andvias.

Item 41. The optical coupling device of any of items 25 through 40,wherein the first piece and the second piece are pieces of an opticalferrule.

Item 42. The optical coupling device of any of items 25 through 40,wherein the first piece is an optical ferrule and the second piece is ahousing of an optical connector.

Unless otherwise indicated, all numbers expressing feature sizes,amounts, and physical properties used in the specification and claimsare to be understood as being modified in all instances by the term“about.” Accordingly, unless indicated to the contrary, the numericalparameters set forth in the foregoing specification and attached claimsare approximations that can vary depending upon the desired propertiessought to be obtained by those skilled in the art utilizing theteachings disclosed herein. The use of numerical ranges by endpointsincludes all numbers within that range (e.g. 1 to 5 includes 1, 1.5, 2,2.75, 3, 3.80, 4, and 5) and any range within that range.

Various modifications and alterations of the embodiments discussed abovewill be apparent to those skilled in the art, and it should beunderstood that this disclosure is not limited to the illustrativeembodiments set forth herein. The reader should assume that features ofone disclosed embodiment can also be applied to all other disclosedembodiments unless otherwise indicated. It should also be understoodthat all U.S. patents, patent applications, patent applicationpublications, and other patent and non-patent documents referred toherein are incorporated by reference, to the extent they do notcontradict the foregoing disclosure.

The invention claimed is:
 1. An optical coupling device comprising: afirst piece comprising: one or more first receiving elements configuredto receive and secure one or more optical waveguides; and one or morelight affecting elements configured to affect one or morecharacteristics of light from the optical waveguides while propagatingthe light within the optical coupling device; and a second piece,separate from the first piece, the second piece comprising: one or moresecond receiving elements configured to receive the waveguides, thefirst receiving elements and the second receiving elements configured toalign the second piece and the first piece using the optical waveguides;and one or more mating alignment features configured to engage with amating optical coupling device and to align the optical coupling devicewith the mating optical coupling device, wherein the first and secondpieces have substantially different shapes, wherein the second piecedefines a cavity defined by opposing top and bottom walls and opposingside walls of the second piece, and wherein the first piece at leastpartially fits within the cavity of the second piece.
 2. The opticalcoupling device of claim 1, wherein the first piece is a first unitarymolded piece and the second piece is a second unitary molded piece. 3.The optical coupling device of claim 1, wherein the second pieceincludes clips configured to hold the first piece.
 4. The opticalcoupling device of claim 1, wherein the first piece includes at leastone mating alignment feature to engage with a socket of a mating opticalcoupling device.
 5. The optical coupling device of claim 1, wherein thefirst piece includes a surface that is configured to slidably mate witha surface of a mating optical coupling device.
 6. The optical couplingdevice of claim 1, wherein the one or more characteristics of the lightpropagating within the optical coupling device include one or more of adirection and divergence of the light.
 7. The optical coupling device ofclaim 1 further comprising an output surface, the light propagatingwithin the optical coupling device exiting the optical coupling deviceafter being transmitted by the output surface, the output surfacedisposed in the first piece.
 8. The optical coupling device of claim 1,wherein the mating alignment features of the second piece compriseforward stops.
 9. The optical coupler of claim 1, wherein the matingalignment features of the second piece comprise arms that extend fromthe second piece, wherein the arms are flexible, and wherein the armsare configured to flexibly engage with sides of a mating opticalcoupling device and to provide lateral mating alignment between theoptical coupling device that the mating optical coupling device.
 10. Theoptical coupling device of claim 1, wherein the first piece and thesecond piece are pieces of an optical ferrule.
 11. The optical couplingdevice of claim 1, wherein the first piece is an optical ferrule and thesecond piece is a housing of an optical connector.